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Ford 6.0L Powerstroke Maintenance Information

Posted by ID Speed Shop on 2023 Jan 3rd

Ford 6.0L Powerstroke Maintenance Information

Let's talk 6.0L maintenance.  Below is a recommended maintenance schedule, along with part numbers and

quantities.  We used severe duty maintenance schedule, since the 6.0L is prone to maintenance concerns. 

Especially as the trucks get older.  


Negligence in maintaining your 6.0L Powerstroke will cause major issues in the long run.  The 6.0L is an HEUI

system, so oil break down and carbon build up will haunt you with injector issues.  Always use synthetic oil and a OE

oil filter.


Stiction is a leading cause of misfires and hard start conditions for the 6.0L Power Stroke. An additive specifically

designed to combat stiction can also help prevent it. If the additional cost of an oil change has you worried, use an

additive every other time the oil is changed; some protection is better than n  o protection. Don't use just any oil

additive; stick to popular additives specifically designed to combat stiction.  Use  Arichoil AR9100 Friction Modifier

regularly, it will save you a ton of money.


We recommend you service your EGR valve every few oil changes.  The valve can be taken out, cleaned, and

reinstalled with new o-rings very quickly and easily. It's a serviceable item that most forget about.  When the EGR

valve clogs, it's stuck in one position and your fuel economy and performance will suffer. A clogged EGR valve can

cause an engine to run hotter than normal, which contributes to head gasket failures. 


Codes for a failed EGR that needs replaced or cleaned:

P0401 - Insufficient EGR flow detected (valve sticking/stuck at or near the closed position)

P0402 - Excessive EGR flow detected (valve sticking/stuck at or near the open position) 

P0404 - Exhaust gas recirculation circuit range/performance (many possibilities, one of which is the valve position is

not matching that commanded by the PCM)

How to remove and reinstall the EGR Valve:

Tools:

8mm socket with extension and ratchet.

Screw driver

Carb cleaner

Pry tool


Time: About 30 minutes, usually less.

Parts- 2 O-rings and 1 gasket.  Give us a call at ID Speed Shop, we can supply.


1)Unplug the EGR Valve 

2)Remove Bolts 

3) Pry straight up

4) Soak the EGR shaft in carb cleaner or spray and brush. Avoid getting cleaner in the 2 holes at the base

of the upper valve. Those holes lead to the upper valve and can damage the valve. Clean the soot off the lower valve

& shaft and in/out let holes. 

5) Replace o rings and gasket, then reinstall.



 

Maintenance/Service Miles Kilometers
Change Oil 5,000 miles 8,000 km
Change Oil
Filter
5,000 miles 8,000 km
Change Fuel
Filter(s)
10,000 miles 16,000 km
Replace Air
Filter
Check Filter restriction
gauge. Replace
as necessary.
Check Filter restriction
gauge. Replace
as necessary.
Flush Cooling
System
Every 40-50,000 miles
or once a year.
64-80,000 km or
once a year.
Replace Auto
Transmission
Fluid
30,000 miles 48,000 km
Replace Manual
Transmission
Fluid
60,000 miles 96,000 km
Change External
transmission filter
30,000 miles 48,000 km
Change internal
transmission filter
30,000 miles 48,000 km
Replace Transfer
Case Fluid
150,000 miles 240,000 km
Replace Rear
Differential Fluid
100,000 miles 160,000 km
Replace Front
Differential Fluid
100,000 miles 160,000 km
Oil/Fluid Capacity – Quarts Capacity – Liters
Engine Oil 15 Quarts /w filter 14.2 Liters
Auto Transmission Fluid 17.5 Quarts 16.6 Liters
Manual Transmission Fluid 5.8 Quarts 5.5 Liters
Transfer Case 2 Quarts 1.9 Liters
Coolant 27.5 Quarts 26 Liters
Front Differential Fluid
(Dana 60)
3 Quarts 2.8 Liters
Rear Differential Fluid
Sterling 10.50″
Dana 80
Dana S110
Dana S130
See Below
3 Quarts
3.5 Quarts
6.98 Quarts
6.98 Quarts
See Below
3.3 Liters
4.0 Liters
6.6 Liters
6.6 Liters
Part Type Part #
Engine Oil For temperatures above 10 degrees
Fahrenheit: 15W40
Motorcraft 15W40
Shell Rotella T4 15W40
Shell Rotella T6 15W40
Engine Oil Filter Ford: 3C3Z-6731-AA
Motorcraft FL-2016
Oil Filter Cap Ford: 3C3Z-6766-CA
Motorcraft EC-781
Fuel Filter Ford: 3C3Z-9N184-CB
Motorcraft FD-4616
Engine Air Filter Ford: 4C3Z-9601-AA
Motorcraft FA-1778
Coolant Motorcraft VC-7-B
Automatic Transmission Fluid
For TorqShift 5R110W Trans
Motorcraft Mercon SP ATF
Manual Transmission Fluid
For ZF
Motorcraft Mercon V
External Transmission
Filter
Motorcraft FT-145
(Re-Use your O-Ring)
Internal Transmission
Filter
Motorcraft FT-144
Transfer Case Fluid Motorcraft Mercon V
Front Differential Fluid SAE 80W-90
Rear Differential Fluid
Sterling 10.50″
Dana 80
Dana S135
Dana S110
Dana S130
See Below *(May need to add Additive)*
SAE 75W-140
SAE 75W-90
SAE 80W-90
SAE 75W-140
SAE 75W-140
Glow Plugs
’03-’04
’04-’07
See Below
Ford 3C3Z-12A342-AA (Motorcraft ZD-12)
Ford 4C3Z-12A342-AA (Motorcraft ZD-13)
Thermostat Ford 3C3Z-8575-AA
Motorcraft RT-1169
EGR Valve
’03-’04
’04-’07
See Below
Motorcraft CX-2467-RM
Motorcraft CX-2466-RM
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